Note: Descriptions are shown in the official language in which they were submitted.
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PRE-FINISHED INSULATED PANEL SYSTEM
FOR CLADDING A BUILDING
TECHNICAL FIELD
[0001] The invention relates to a pre-finished insulated
panel system for cladding a building with rectangular
panels having interlocking and overlapping joints, and
mounted to the building wall with adhesives and mechanical
fasteners hidden in the joints.
BACKGROUND OF THE ART
[0002] Conventional exterior insulated finishing systems
(EIFS) for building construction include insulating foam
cores that are cut with a hot wire to a desired profile,
externally covered with self-adhering reinforcing mesh and
then extrusion coated with various coatings for
weatherproofing, visual effects and durability. Final
coating may be applied on a building site but in general
pre-finished fully manufactured components are preferred
due to better quality control, lower cost and consistent
finish. Prefinished EIFS components include prefabricated
panels and trim components to surround doors and windows.
[0003] All EIFS components have an insulating foam core
coated with weatherproof coating to provide an externally
installed insulated finished wall. The foam core serves to
supplement or completely replace internally installed
insulation such as spray foam or flexible fibrous
insulation batts.
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[0004] Pre-finished and pre-fabricated EIFS systems have
replaced traditional foam insulation boards coated on site
with stucco due to cost, quality, and speed of
installation. US Patent 5987835 and US Patent Publication
2006/0185299 describe examples of EIFS systems using
partially or fully pre-finished panels.
[0005] Moisture penetration has caused problems with
corrosion and other water damage to the underlying building
components of the exterior wall covered with an EIFS
system. Wind and rain tend to drive moisture through
joints and cracks in the EIFS cladding. Moisture barriers
are provided between the underlying building substrate and
the EIFS cladding. Drainage grooves on the inside surface
of EIFS panels drain the trapped moisture and direct water
to bleed holes in the base of the EIFS cladding.
[0006] It is desirable to produce a pre-finished EIFS
cladding system that reduces on-site labour costs, improves
quality and reliability.
[0007] Features that distinguish the present invention
from the background art will be apparent from review of the
disclosure, drawings and description of the invention
presented below.
DISCLOSURE OF THE INVENTION
[0008] The invention provides a pre-finished insulated
panel system for cladding an exterior wall of a building,
the wall including a supporting structural substrate, the
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system comprising: a plurality of rectangular panels,
wherein each panel has an insulation core and weather
resistant coating defining a central portion with a panel
thickness between an inside mounting surface and an exposed
outside surface, a top edge, a bottom edge, and opposing
lateral edges, the plurality of panels adapted for
engagement in a series of parallel rows; each panel having:
a mounting flange disposed on the top edge and on a first
lateral edge of each panel, the mounting flange including:
a recessed mounting groove; an inner ridge; and an outer
ridge; an elongate cover flange complementary with the
mounting flange disposed on the bottom edge and on an
opposing second lateral edge, the cover flange including:
an inner groove complementary to the inner ridge; and an
outer groove complementary to the outer ridge; and
mechanical fasteners having a fastener head disposed within
the recessed mounting groove and a shank for anchoring in
the supporting structural substrate.
DESCRIPTION OF THE DRAWINGS
[0009] In order that the invention may be readily
understood, one embodiment of the invention is illustrated
by way of example in the accompanying drawings.
[00010] Figure 1 is a perspective vertical elevation view
of a partially installed exterior wall covered with the
pre-finished insulated panel system described herein.
[00011] Figure 2 is a detail view of the bottom two rows
of panels of the system, in particular showing the bottom
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starter flashing strip, bottom row of starter panels with a
drip edge, and the second row of regular or intermediate
panels installed with screw fasteners and elongate washers
to the building wall substrate.
[00012] Figure 3 shows an exterior elevation view of a
wide panel where the top and left edges include mounting
flanges and the bottom and right edges include overlapping
and interlocking cover flanges.
[00013] Figure 4 shows a section view along line 4-4 of
Fig. 3.
[00014] Figure 5 shows a section view along line 5-5 of
Fig. 3.
[00015] Figure 6 shows an exterior elevation view of a
narrow panel similar to the wide panel of Figs. 3-5.
[00016] Figure 7 shows a section view along line 7-7 of
Fig. 6.
[00017] Figure 8 shows a section view along line 8-8 of
Fig. 6.
[00018] Figure 9 shows a detail view of the left portion
of the narrow panel of Figure 6.
[00019] Figure 10 shows a section view along line 10-10
of Fig. 9.
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[00020] Figure 11 shows a sectional view through a
starter panel also shown as the first row of panels in
Figure 2.
[00021] Figure 12 shows a sectional view through a
regular or intermediate panel and a partial broken section
of an interlocking and overlapping panel above.
[00022] Figure 13 is a partial vertical sectional view
through an example ground level building structure with an
exterior wall covered with a starter flashing strip and a
starter panel.
[00023] Figure 14 is a partial vertical section view
through the upper wall, eaves and rafter portion of an
exterior building structure showing a square framing strip
and abutting top panel joined above the soffit.
[00024] Figure 15 is a vertical sectional view through a
lintel above a window opening showing the EIFS cladding
including a decorative molding trim covering a framing
strip and the joint of an abutting panel above.
[00025] Figure 16 is a horizontal sectional view through
the exterior left jamb of a window opening showing the EIFS
cladding including an L-shaped molding trim covering a
framing strip and the joint of an abutting panel to the
left side.
[00026] Figure 17 is a vertical sectional view through a
sill below a window opening showing the EIFS cladding
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including a decorative molding trim covering a framing
strip and the joint of an abutting panel below.
[00027] Figure 18 is a horizontal sectional view through
an outside corner showing an L-shaped outside corner strip,
abutting panels of equal thickness on both sides of the
corner strip, and an L-shaped decorative trim strip
covering the outside corner strip and the abutting joints
with the panels.
[00028] Figure 19 is a horizontal sectional view through
an inside corner showing an L-shaped inside corner strip,
abutting panels of equal thickness on both sides of the
corner strip, and an L-shaped decorative trim strip
covering the inside corner strip and the abutting joints
with the panels.
[00029] Figures 20 and 21 are horizontal section views
through an alternative outside and inside corner
respectively, where the panels are mitered 45 degrees with
the cut surfaces adhered together to produce a simple
corner without overlapping components.
[00030] Figure 22 is a detail of the screw fastener,
elongate trapezoidal washer and trapezoidal mounting groove
also seen in Figure 2 middle-left.
[00031] Further details of the invention and its
advantages will be apparent from the detailed description
included below.
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[00032] Figure 1 shows a perspective vertical elevation
view of an exterior wall 1 partially covered with pre-
finished insulated panels 2. Figures 2 and 13 show the
typical construction of a wood frame building with an
exterior supporting structural substrate of oriented strand
board 3 but the specific nature of the board 3 and frame
structure could be any common type that produces a
generally flat vertical wall surface.
[00033] Referring to Figure 13, common wood frame
construction used in North America begins with a concrete
foundation wall 4 extending above the adjacent ground
surface 5. The wood frame building includes a sill plate 6,
floor joists 7, a rim joist 8, floor board 9, wall plate 10
and wall stud 11 to support the exterior sheathing board 3.
[00034] As seen in Figures 2 and 13, to weatherproof the
board 3, prevent moisture penetration into the board 3 and
drain away any moisture accumulation, the installation of
the panel system includes an air-moisture barrier coating
12. An adhesive coating 13 adheres the exterior insulating
panel system to the supporting board 3. At the bottom of
the starter panel 14, a starter flashing strip 15 made of
PVC (polyvinyl chloride plastic) is installed to direct any
moisture blocked by the moisture barrier 12 and adhesive 13
downward and outward. The adhesive 13, which is also a
moisture barrier, outwardly overlaps the starter flashing
strip 15 to bond the lower portion of the starter panel 14
and direct moisture outwardly.
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[00035] As seen in Figures 2 and 22, the starter panel 14
and intermediate panels 2 are mounted to the board 3 with
adhesive 13 and mechanical fasteners comprising wood screws
16, and an elongate washer 17. As best seen in Figure 22,
the washer 17 includes a countersunk socket 18 to
accommodate the head of the screw 16. The washer 17 is
trapezoidal and fits into a trapezoidal mounting groove 19.
The mechanical fastener arrangement is flush to the
mounting flange 20, avoids interference with the
overlapping cover flange 26, and distributes the load from
the screw 16 over a large area of the mounting groove 19 to
avoid crushing damage. The screws 16 and washers 17 secure
the panels 2, 14 in place during installation until the
adhesive 13 is cured and fully bonded.
[00036] Figures 3-5 show a wide version of the panel 2,
whereas Figures 6-8 show a narrow version which is
identical in all respects except for the width of the
panel. The panels 2 can be installed horizontally as in
Figure 1 or vertically, and wide and narrow panels 2 can be
installed in alternating rows to achieve various visual
effects.
[00037] It is common practice in manufacturing insulating
foam panels and trim members to cut the various foam core
shapes from a large foam block using a CNC controlled hot
wire cutter. The foam core has a uniform cross-sectional
profile as a result of the hot wire path carved through the
foam block. In order to produce the shapes shown in
Figures 3-5 and 6-8, two stages of hot wire cutting are
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required. For example, in a first stage the hot wire
operates longitudinally and cuts the cross-sectional
profile shown in Figures 4 and 7. In a second stage, the
hot wire operates transversely and cuts the left and right
edges to achieve the cross-sectional profile as shown in
Figures 5 and 8.
[00038] Each panel 2 has an insulation foam core and
weather resistant coating which can include a reinforcing
mesh layer and multiple coats of cementitious or non-
cementitious materials. Various surface effects can be
applied to the exposed outside surface 22 such as colors,
surface textures and granules. The generally rectangular
panels 2 have a central portion with a uniform panel
thickness between the inside mounting surface 23 and the
exposed outside surface 22. In Figures 3, 6 and 9 the
dashed lines indicate that the inside mounting surface 23
includes drainage grooves 24 formed in circular shapes by
removing foam material with a rotating cutter for example.
The drainage grooves 24 are also visible in Figures 11-21
and provide a drainage path for any trapped moisture to
escape by flowing downward under gravity. The top edge,
bottom edge, and opposing lateral edges are profiled to
interlock and overlap the edges as shown in Figure 12 for
example.
[00039] When installed (Fig. 1-2 for example) the panels
2, 14 are arranged in a series of parallel vertical rows,
parallel horizontal rows or in other patterns such as
herringbone. As seen in Figures 3 and 6, each panel 2 has
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a mounting flange 20 disposed on the top edge and on one
lateral edge. In the embodiments shown in the drawings,
the mounting flange 20 is on the left edge but it could be
located on the right edge to equal effect. The mounting
flange 20 includes a recessed mounting groove 19 (see Fig.
22) to retain the elongate trapezoidal washer 17 and
mounting screws 16.
[00040] As seen in Figures 11-12, the mounting flange 20
includes an inner ridge 25 and an outer ridge 29 which
serve to wedge interlock with the bottom edge of a row of
panels 2 subsequently installed from above. The elongate
cover flange 26 is complementary in cross-sectional profile
shape with the mounting flange 20. The cover flange 26 in
the embodiments shown is disposed on the bottom edge and on
the right lateral edge to engage the opposing left lateral
edge of an adjacent panel 2. As seen in Figure 12, the
cover flange 26 includes an inner groove 27 complementary
to the inner ridge 25, and an outer groove 28 complementary
to the outer ridge 29.
[00041] The mechanical fastener screws 16 have a fastener
head that is countersunk within the elongate washer 17
within the recessed mounting groove 19 and a helical screw
shank for anchoring in the supporting oriented strand board
3. As indicated in Figure 12, the screw head and washer 17
are flush mounted within the mounting groove 19 and do not
interfere with the sliding insertion of the cover flange
26. It will be understood that the same use of screws 16
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and washers 17 occurs on the lateral edges that have
mounting grooves 19 as well.
[00042] The ridges 25, 29, the grooves 19, 27, 28 and the
exterior exposed surface 22 of each panel is coated with
weatherproof materials. Wind forces on a building can
include pressure differentials that create a vacuum that
tends to draw moisture into any joints or cracks in the
exposed surface. Further, capillary action can draw
moisture from the surface into joints. The tight wedging
fit of the interlocking ridges 25, 29, and grooves 27, 28,
the weatherproof coating of joint surfaces, the moisture
barrier 12 and drainage grooves 24 serve to resist
migration of moisture through the joints and to drain away
any moisture from the inside mounting surface 23 of the
panels 2.
[00043] The wedge interlocking of ridges 25, 29, and
grooves 27, 28 is sufficient to secure the cover flange 26
without using adhesives or caulking in the joint.
Referring to Figures 11-12 the inner ridge 25 has an inner
detent surface 30 to engage and abut the inner groove 27.
The inner detent surface 30 is disposed at an obtuse angle
"a" relative to the inside mounting surface 23. Referring
to Figure 12, the cover flange 26 includes an inward wedge
31 defined between the inside mounting surface 23 and the
inner groove 27. When the upper row of panels 2 is
installed in a downward sliding motion, the inward wedge 31
is wedged between the supporting board 3 and the sloped
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inner detent surface 30 of the previously installed lower
panel 2.
[00044] In a similar manner, the outer ridge 29 has an
outer detent surface 32 to abut the outer groove 28. The
outer detent surface 32 is disposed at a second obtuse
angle "b" (Fig. 11) relative to the inside mounting surface
23 of the panel 2. The cover flange 26 provides an outward
wedge 33 (Fig. 12) defined between the outer groove 28 and
the inner groove 27. The outer wedge 33 engages the sloped
outer detent surface 32 and exerts a force driving the
cover flange 26 toward the adhesive 13 and wall board 3.
[00045] The wedging forces exerted by the interaction of
the sloped detent surfaces 30, 32 and the wedges 31, 33
drives the cover flange 26 inwardly to ensure that the
adhesive 13 bonds sufficiently to the inside mounting
surface 23 of each panel 2. The screws 16 secure the
mounting flange 20 even if adhesive remains fluid and
prevent the inward wedge 31 from prying the mounting flange
outward away from the board 3.
[00046] Referring to Figure 12, the cover flange 26
includes a flap 34 defined between the outer groove 28 and
the exposed outside surface 22 of the panel 2. In the
embodiment shown, the flap 34 provides a drip edge and is
spaced from the panel 2 below to provide a visual reveal
feature. The flap 34 could also be extended downward to
eliminate the reveal and abut the panel 2 below. For
example, the reveal can be eliminated in oints on the
lateral edges of adjacent panels 2 in the same row.
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[00047] Referring to Figure 13, the installation of the
panel system commences with the installation of the PVC
starter flashing strip 15. As seen in Figure 11, the row
of starter panels 14 is then installed using the same
mounting flange 20 disposed on the top edge and side edge
using the recessed mounting groove 19, washers 17 and
screws 16. The starter panels 14 have no other panels
below and instead have a drip flange 35 disposed on the
bottom edge. As shown in Figure 13, the starter flashing
strip 15 in the installation is hidden in a groove inward
of the drip flange 35 between an inside mounting surface 23
of the starter panel 14 and the supporting structural board
3.
[00048] Figure 14 shows partial vertical section view
through the exterior wall top plate 36, roof rafter 37 and
soffit 38. The insulated cladding system includes a square
framing strip 39 and abutting square ended top panel 40
that have a joint 38 above the soffit 38. Like the panels
2, 14 and 40 the framing strip 39 has an insulation core
and weather resistant coating. The framing strip 39 has a
thickness equal to the thickness of the panel 40, and
provides an abutment surface to secure the top edge of the
top panel 40. The top panel 40 has a rectangular abutment
flange on the top edge for abutting the top finishing strip
39. The top edge may be pre-finished during manufacturing
if the wall height is known in advance or may be trimmed on
site having a raw uncoated foam top edge as a result. The
top panel 40 has the same elongate cover flange 26
complementary with the mounting flange 20 disposed on the
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bottom edge and on a lateral edge to interlock and overlap
a panel 2 below and laterally.
[00049] As shown in the window framing examples of
Figures 15-17 a square framing strip 39 is installed around
a window or door opening to abut the adjacent panels 2.
The framing strip 39 and joint with the panel 2 is covered
with a decorative trim molding 41 and drip flashing 42 to
surround the window 43.
[00050] Figures 18 and 19 show a first alternative for
inside and outside corners. Figure 1 also illustrates
these corner treatments. Figure 18 shows an L-shaped
outside corner strip 44 that provides a vertical abutment
for the lateral ends of adjacent panels 2 which have been
trimmed on site to a square end. The outside corner strip
44 and joints with the adjacent panels 2 are covered with
an L-shaped outside corner trim strip 46. Figure 19 shows
an L-shaped inside corner strip 45 that provides a vertical
abutment for the lateral ends of adjacent panels 2 which
have been trimmed on site to a square end. The inside
corner strip 45 and joints with the adjacent panels 2 are
covered with an L-shaped inside corner trim strip 47.
[00051] Figures 20 and 21 are horizontal section views
through an alternative outside and inside corner
respectively, where the panels 2 are mitered 45 degrees
with the cut surfaces adhered together with sealant to
produce a simple corner without overlapping trim strips 46,
47.
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[00052] Although the above description relates to a
specific preferred embodiment as presently contemplated by
the inventor, it will be understood that the invention in
its broad aspect includes mechanical and functional
equivalents of the elements described herein.
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